U.S. patent application number 12/804415 was filed with the patent office on 2011-03-24 for durable shipping container for heavy sensitive electroinics.
This patent application is currently assigned to MSE INNOVATIONS LLC. Invention is credited to Adam Richard Egan, Elizabeth Gale Egan, Martin Shawn Egan.
Application Number | 20110068035 12/804415 |
Document ID | / |
Family ID | 43755712 |
Filed Date | 2011-03-24 |
United States Patent
Application |
20110068035 |
Kind Code |
A1 |
Egan; Martin Shawn ; et
al. |
March 24, 2011 |
Durable shipping container for heavy sensitive electroinics
Abstract
A system and method for securing, shipping, storing, loading,
unloading, accessing and protecting sensitive heavy electronic
assemblies. Integration of container dunnage, recessed hardware and
exterior stacking features to protect container and contents during
shipping.
Inventors: |
Egan; Martin Shawn;
(Ballwin, MO) ; Egan; Elizabeth Gale; (Ballwin,
MO) ; Egan; Adam Richard; (Ballwin, MO) |
Assignee: |
MSE INNOVATIONS LLC
Ballwin
MO
|
Family ID: |
43755712 |
Appl. No.: |
12/804415 |
Filed: |
July 21, 2010 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61277104 |
Sep 21, 2009 |
|
|
|
Current U.S.
Class: |
206/523 |
Current CPC
Class: |
B65D 2519/00174
20130101; B65D 81/113 20130101; B65D 21/0223 20130101; B65D
2519/00666 20130101; B65D 2519/0081 20130101; B65D 19/18 20130101;
B65D 25/2852 20130101; B65D 2519/00318 20130101; B65D 2519/00208
20130101; B65D 2519/00791 20130101; B65D 2519/00034 20130101; B65D
2519/00621 20130101; B65D 2519/00965 20130101; B65D 2519/00069
20130101; B65D 2519/00711 20130101; B65D 2313/00 20130101; B65D
2519/00338 20130101; B65D 2585/86 20130101 |
Class at
Publication: |
206/523 |
International
Class: |
B65D 81/02 20060101
B65D081/02 |
Claims
1. A shipping container comprising: a generally rectangular body of
surrounding material containing a first component and a second
component for opening and closing together providing access to a
interior space defined by the surround material, each component
containing an alignment, sealing profile and gasket extending along
the mating edge of the first and second component; first and second
components containing exterior mounted slip hinges between the
first and second component spaced at increasing intervals to
promote assembly along one mating edge allowing rotation and
component separation; first and second components containing one or
more latches positioned opposite hinges; first component lid
containing recessed pockets promoting stacking and horizontal
alignment between second component base when stacked, end mounted
lift handles to gain access to cargo; second component base
containing one or more recessed and covered tie downs; First and
second Component containing large radius exterior vertical corner,
horizontal edge and surface features; First and second components
containing conforming interior features for shipping components and
reducing internal air volume; First and Second component containing
curved support surfaces with attached contouring dunnage at
opposing ends; First and Second component containing curved support
surfaces with attached contouring dunnage that divides the
container into segments; First and second component containing
internal arch features transferring weight between the two
components; First and Second components containing storage
configurations for one or more cargo assemblies; second component
containing features allowing complete access to one or more cargo
assemblies without removal of dunnage, vibration, shock and impact
reducing skid plate assemblies; First and second component
comprising end mounted security hasp preventing access; Second
component or base comprising pressure release valve or option;
first and second components comprised of composite materials
forming hollow compartments filled with polyurethane foam or energy
dampening material.
2. The shipping container as claimed in claim 1 further including
skid plate assemblies containing skid plates manufactured with
composites, steel or wood; impact dampening, vibration and shock
isolators materials including Sorbothane, rubber, commonly used
materials, one or more springs and containers of air to cushion
impact energy.
3. The shipping container as claimed in claim 1 further including
integrated interior cargo cushioning pads manufactured with
Sorbothane, rubber, commonly used materials for impact, damping,
vibration and shock reduction.
Description
TECHNICAL FIELD
[0001] This disclosure is generally directed to consumer and,
commercial products for shipping sensitive heavy electronic
equipment by over night express carriers.
[0002] Applicable U.S. patent Classification Definitions include,
descriptions in Group III 414-224 788.1 Package and Article
Carriers, 220-190 1.5 Freight Container and 220-206 Special
receptacles or Packages.
BACKGROUND
[0003] There is currently a need for shipping containers for heavy,
sensitive electronic equipment to be shipped routinely. Over night
carriers have size and weight limitation for overnight shipments.
Our investigation into the shipping requirements and
design/engineering time has resulted in the invention being
described.
[0004] Currently heavy electronic equipment is shipped in metal or
wood based crates that exceed weight and dimensional limitations
for overnight express shipments. Metal and wood shipping containers
have additional expense and shipping limitations. The current
container systems are heavy and require forklifts to move even when
empty. An opportunity exists to design/engineer an alternative
shipping container' that would reduce shipping expense and
time.
[0005] Our investigation in this design challenge helped define a
number of consumer needs integrated into our design.
[0006] The container should be able to ship empty, half full or
completely full. Shipments can include single components and an
assembly of components. Users of the container would benefit if
they could gain access to one complete set of components without
removal of the other set.
[0007] Our investigation found most containers for shipping
electronics use gray shipping foam, paper, small bags of air or
polyurethane foam bag packs (dunnage) that fit around the items to
be shipped. These systems require the removal of dunnage material
to gain access to the items being shipped. The removal of dunnage
can result in loss of dunnage not replaced in the proper position.
An opportunity exists to improve on placement and use of
dunnage.
[0008] It would be beneficial if the container had replaceable skid
pads. Due to the weight of the items being shipped and sensitivity
of the electronics, an opportunity exists to design a skid pad that
reduces impact, extends wear and promotes transporting.
[0009] Quick lid removal is also desired. Current over night wood
and metal container systems including crates can require the use of
common hand tools to gain access. Our investigation of lid
retaining and removal highlighted an opportunity to improve this
process by eliminating the need for tools.
[0010] Investigation into container requirements highlighted the
need for rope tie downs to hold containers in position during
transit. It would be an improvement to include rope tie downs on a
plastic container meeting the size limitation for overnight
carriers.
[0011] Our Investigation into container requirements highlighted
the need to eliminate sharp corners that could present harm to
users, surrounding cargo and surfaces during transit on a plastic
container.
[0012] Our Investigation into container requirements highlighted
the need to protect hardware from damage, weather and unwanted
access. It would be an improvement to design a plastic container
protecting hardware from damage, weather and unwanted access for
overnight carriers.
[0013] Investigation into container requirements highlighted the
need to transfer container by use of fork lift, lift trucks and
promote stack ability on a plastic container. It would be an
improvement if these features can also be incorporated into a
plastic shipping container.
[0014] Investigation into the container requirements highlighted
the need for shock and isolation systems to reduce damage to
sensitive electronics. It also highlighted a need for heavy
sensitive electronics needing additional support over long periods
of time. Again as it relates to plastic shipping containers.
[0015] Investigation also highlighted the need to protect hardware
from the elements including water, ice, dust, sand, frost and mud.
Providing protection will promote proper use and could eliminate
injury. It would be an improvement if these features are also
included on a plastic storage container meeting size limitation for
over night carriers.
[0016] It would be an improvement to incorporate a dunnage system
the allows users access to one complete component assembly leaving
one or more assemblies stored and retained by dunnage that is
integrated with the container.
BRIEF SUMMARY OF THE INVENTION
Summary Overview
[0017] This Non Provisional application is being submitted and
references the provisional application 61/277,104 with a filing
date of Sep. 21, 2009. This disclosure provides a system and method
for storing, shipping, loading, unloading, accessing and protecting
sensitive heavy electronics during transit by overnight carriers.
This disclosure also provides a system and method for accessing
components stored inside container.
[0018] Multiple Assemblies
[0019] According to one embodiment of the present disclosure, the
container stores one or more assemblies including accessories and
provides access and removal of one full set of components for use.
Storage of items is symmetrically designed allowing removal of one
full component assembly and all accessories. The container is
designed to maintain a safe operating condition allowing shipping
in all configurations including empty.
[0020] Dunnage
[0021] In yet another embodiment, the present disclosure provides
an apparatus and method to organize and simplify dunnage. Due to
sensitive electronics, our design uses sorbothane material that is
permanently fixed inside the container. This reduces the chance of
dunnage being lost, misplaced or misused. Because our dunnage
material is integrated into the design and stays inside the
container, our design is user friendly eliminating questions on
placement. It allows access to a wide range of parts. Various types
of dunnage materials can be used based on sensitivity of electronic
equipment.
[0022] Container Surfaces
[0023] Container surfaces are curved, promoting good part design
and quality. The interior space can be formed to fit a wide range
of items being shipped. This will result in less air space and
moisture inside the container which could damage electronics.
[0024] Skid Pad Design
[0025] In yet another embodiment, the present disclosure provides
an apparatus and method for reducing shock. The skid pads have been
designed using common available components allowing field
replacement. The pad consists of a round wood skid, sorbothane
isolator, bolt, washer sleeve and other common components. The
design allows movement in the vertical direction should the
container be dropped. Sorbothane isolators will expand outward
reducing the impact to the container. The washer sleeve allows
proper spacing and movement of these components.
[0026] Toolless Lid Removal
[0027] In yet another embodiment, the present disclosure features a
lid that can be removed without the use of any tools. Incorporating
the use of slip style hinges on this plastic shipping container
will allow the lid to be slid off pivot pins without the use of
tools. The placement of our hinges has been staggered to promote
easy assembly when aligning and reinstalling the lid on the pivot
pins. In addition the lid and base features a nylon strap to use as
a lid stay system to prevent accidental rotation of the lid
reducing damage and injury to users.
[0028] Tie Downs
[0029] In yet another embodiment, the present disclosure provides
an apparatus and method to provide tie downs placed on the lid or
base as needed. Inserts in tooling will allow placement in either
position. The ties downs can be positioned under an over hang
protecting them from the elements. When they swing out to 90 degree
the user has full access.
[0030] Rounded Aesthetics
[0031] In still another embodiment, the present disclosure provides
a rotational or blow molded container with both interior and
exterior features to support cargo. Wide ranges of material are
available depending on operating conditions. Both of these
processes require generous radius corners to promote good parts. In
addition these rounded corners improve the container function in
tight spaces, preventing it from catching edges. The large corners
will also prevent damage to other cargo containers and injury to
workers.
[0032] Stacking Feature
[0033] In still another embodiment, the present disclosure provides
a system and apparatus to carry heavy loads of sensitive
electronics. Estimated loads could exceed 530 lbs total including
the container. Our container is designed to maximize space by
allowing user to stack the container. Interlocking closing features
hold the lid and base in position and direct force straight down at
the joint. In addition, large radius corners help transfer force
away from the cargo and down to the ground. Large centering
features prevent movement unless the container is picked up in a
vertical direction. We have also provided clearance for forklift
tines between the lid and base when stacked.
[0034] Interior Sorbothane Isolation
[0035] In still another embodiment, the present disclosure provides
a system and apparatus to prevent damage from shock and impact to
cargo inside the container. We have positioned sorbothane material
in key position inside the container as needed to reduce damage to
the cargo. Polyurethane foam is also used throughout the container
for structure and to reduce the transmission of shock energy.
Depending on the items being shipped, foam density can be adjusted
to improve dampening effects.
[0036] Accessory Storage Pack
[0037] In yet another embodiment, the present disclosure provides
an apparatus and method for providing two areas to store accessory
components. Components would be secured in standard foam packing
material cut to fit profiles. These accessory packs can be removed
or permanently fixed inside the container using adhesive
material.
[0038] Recessed Hardware
[0039] In still another embodiment, the present disclosure includes
the recessed placement of hardware to protect it from the elements
including rain, snow, ice dust, mud and frost. The recessed area
will also obtain less sunlight reducing the amount of UV exposure.
The recessed areas are designed to allow clearance when hardware is
in the operating position.
DRAWING LIST
[0040] FIG. 1a Container Assembly 3/4 View
[0041] FIG. 1b Container Lid Removed and Cargo 3/4 View
[0042] FIG. 1c Container Base and Dunnage Location 3/4 View
[0043] FIG. 1d Container Bottom 3/4 View
[0044] FIG. 2a Container Lid Top 3/4 View
[0045] FIG. 2b Container Lid Bottom 3/4 View
[0046] FIG. 3 Skid Pad Assembly
[0047] FIG. 4 Slip Hinge Assembly and Detail View
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] For a more complete understanding of this disclosure and its
features, reference is now made to the following description, taken
in conjunction with the accompanying drawings, in which:
[0049] FIG. 1a is a somewhat simplified illustration of a shipping
container assembly according to one embodiment of the present
disclosure; this illustration shows the container lid, base,
recessed latches, tie downs, handles, and pressure relief valve
port, end lift handles and hasp, gasket, forklift access point and
stacking features.
[0050] FIG. 1b is a somewhat simplified illustration of a shipping
container with lid removed and heavy sensitive electronic cargo
installed. This illustration shows dunnage how dunnage that would
be retained with the lid cushions the cargo during shipping. It is
position in this image to communicate that it is round in
configuration and conforms to the lid interior. The illustration
shows the container base, recessed latches, tie downs, handles, and
pressure relief valve port, end lift handles and hasp, gasket,
forklift access point, Lid dunnage, heavy electronic cargo and base
mating features.
[0051] FIG. 1c shows a somewhat simplified illustration of a
shipping container with lid and cargo removed. The image highlights
interior features that conform to the cargo at the same time
providing two accessory storage compartments at opposing ends. It
highlights container features that help support heavy sensitive
electronics.
[0052] FIG. 1d shows a somewhat simplified illustration of a
shipping container assembly from a bottom view. This illustration
highlights skid pads and structural support pads to help transfer
weight and align containers when stacked.
[0053] FIGS. 2a and 2b are somewhat simplified illustrations of the
shipping container lid. FIG. 2a highlights recessed stacking and
latch features along with the end lift handle and hasp. FIG. 2b
highlights interior surfaces that are conformed to fit cargo. The
image also shows a recessed pocket that mates features on the
container base.
[0054] FIG. 3 is an somewhat simplified illustration of the skid
pad design for shipping, impact and vibration reduction;
[0055] FIG. 4 is a somewhat simplified illustration of the slip
hinge system.
ADDITIONAL DETAIL DESCRIPTION
Project Review
[0056] The durable shipping container has been invented to protect
expensive sensitive electronics during shipping and handling.
Severe impact to electronic equipment could render it inoperable
thus requiring service, time and cost. The container is designed to
support shipping by overnight express carrier one or more
electronic component assemblies and meet carrier shipping size and
weight limitations.
[0057] Shock and Vibration Isolation Systems
[0058] We have engineered a container that will not only store
items but incorporates key features to reduce shock levels if the
container is dropped. Our solution uses advanced visco-elastic
polymer materials (Sorbothane) known to reduce, absorb and
dissipate shock energy by transferring the shock wave 90 degrees
from the direction of impact and turning that energy into small
amounts of heat. Other commonly known vibration and shock isolation
materials can be used.
[0059] Isolation Rings
[0060] FIG. 3 shows a simplified illustration of a skid pad
assembly used to reduce shock and vibration. Because the container
is designed to ship expensive electronics we have incorporated
isolation rings specifically designed for shipping pallets of
electronics. Isolation rings 301 are integrated into the container
base FIG. 1d profile as part of the skid pad assembly. The
isolation rings 301 are placed between the skid plate 302 and the
container base 100. The rings 301 are designed to absorb shock and
vibration. A metal sleeve 303 allows the assembly to move for
compression. The assembly is attached to the container with a bolt
304. Washers 305 & 307 are used help space the components. This
allows location of the pad assembly and compression of the
Isolation ring 301.
[0061] Container Features
[0062] Rotational molding is a unique method allowing the creation
of both interior and exterior features on a hollow part. We will
fill this hollow part with polyurethane foam which will provide the
structure needed to support the cargo 101. The polyurethane foam
can be formulated in various densities and will also absorb energy.
Other common plastic manufacturing processes including blow can be
used to generate hollow parts.
[0063] Cargo Isolation
[0064] We have designed a second layer of defense against impact
and vibration that will allow for customization. The use of
cushioning pads 102 material at strategic locations to cost
effectively contains impact and vibration will promote safe
shipment of electronic equipment. Cushioning pads 102 have been
placed at supporting point 103 inside of the container.
[0065] Hardware
[0066] Our design incorporates lockable over center latches 104 and
separating hinges 105 allowing lid removal without the use of
tools. In addition, we have incorporated eight swing style handles
106 with 90 degree stops and return springs. Handles 106 are
aligned on opposite sides of the container. Hardware will be
fastened to the container by nut and bolt 107, screw anchor or
retaining plates located on the inside surface.
[0067] Security Seals
[0068] We have provided hasps 108 for common security seals at both
ends of the container. In addition each of our latches contains a
hasp area for security tags and lock. Our design allows
modification of tooling near latch area 109 for lock access.
[0069] Handling Compatibility.
[0070] Our container has been designed for use by pallet jack,
forklift with tines, loaders, lift truck and trailer use. We have
two way accesses 110 from either side while on flat surfaces or
stacked 201. To help provide support and structure the container
design includes skid plate mounting pads 111.
[0071] Portability
[0072] We have designed the container with eight spring loaded
handles 106 allowing it to be carried by 2,4,6 or 8 people as need
and available.
[0073] Handle Selection and Placement
[0074] Eight handles 106 have been provided allowing the container
to be picked up by 2,4,6 or 8 persons. The handles have been placed
high the base 100 to reduce the distance from the bottom of the
container to the ground in case it is dropped. In addition, the
handles are placed above the center of gravity for the container
making it easier to control and carry. Handles feature return
springs, 90 degree stop and artic glove access. The handles have
been positioned inside recessed pockets 112 that will prevent them
from being damaged during shipping but allow full access. This
recess also provides protection from the weather elements. Handle
are aligned and on opposite sides of the container.
[0075] Interior Storage
[0076] The container is designed to provide storage for long items.
Support surface 102 have been provided on either end of the
container. This allows support for the storage of these items and
allows access and storage of items below. Large storage areas have
also is provided for accessory items.
[0077] Breather Valve
[0078] A breather valve port 115 has been located on the front
surface of the container 100 for easy access and service.
[0079] Tie Downs
[0080] Multiple Tie downs 116 have been located on the front and
rear surfaces of the container for easy access, service and
securing the container during shipping.
[0081] Expansion Room
[0082] Due to the containers length and size, the lid pocket 204
for the Base hem 117 has been increased on the ends of the
container allowing additional room for material expansion.
[0083] Hinge Selection and Placement
[0084] Four hinges 400 have been placed opposite of the latches
113. The hinges are designed to be secured on either the vertical
or horizontal surface of the container 100 and Lid 200. Hinges
selected will allow for easy removal by sliding in one direction
and separating lid assembly 200 from base assembly 100. The lid 200
is also designed to be removed for improved access to equipment 101
located in the base container 100. A male and female hinge 400
system allows the lid to be rotated open 180 degrees and then slid
off stud pins 401.
[0085] Lid Features
[0086] The top surface of the lid 200 has been designed to promote
stacking of this container during storage. Contours on the lid
surface 202 have been designed to accept skid plate assemblies 400
and limit movement in three directions. Contours on the surface 202
have also been designed to shed water and prevent collection of
water in pockets 201 and 203. To promote good part design, the top
surface is slightly curved 200, 201, 202 and 203 to prevent oil
canning during the manufacturing process and part removal
process.
[0087] It may be advantageous to set forth definitions of certain
words and phrases used throughout this patent document. The terms
"include" and "comprise," as well as derivatives thereof, mean
inclusion without limitation. The term "or" is inclusive, meaning
and/or. The phrases "associated with" and "associated therewith,"
as well as derivatives thereof, may mean to include, be included
within, interconnect with, contain, be contained within, connect to
or with, couple to or with, be communicable with, cooperate with,
interleave, juxtapose, be proximate to, be bound to or with, have,
have a property of, or the like.
[0088] While this disclosure has described certain embodiments and
generally associated methods, alterations and permutations of these
embodiments and methods will be apparent to those skilled in the
art. Accordingly, the above description of example embodiments does
not define or constrain this disclosure. Other changes,
substitutions, and alterations are also possible without departing
from the spirit and scope of this disclosure, as defined by the
following claims.
* * * * *